Bathtub package

ABSTRACT

A shipping container is described for large, heavy plumbing fixtures, such as bathtubs and the like. The container includes a pair of cut and scored end frames that are positioned at each end of the bathtub in combination with a pair of separate cushioning pads, and, a continuous wrapper element which encloses the bathtub. The wrapper is secured to the sides of the end frames and includes top, bottom and side panels which extend around the bathtub to provide a durable, convenient, and inexpensive shipping container.

[451 Aug. 19, 1975 United States Patent 1191 Goodsite 15 1 BATHTUB PACKAGE 3,757,935 9 1973 Coons et 206/320 R18 892 7 1933 G 229 14 C [75] Inventor: James R. Goodsite, Sandusky, Ohio Omes [73] Westvaco Corporation, New York,

Assignee:

Primary liraminerLeonard Summer Feb. 20, 1974 Appl. No.: 444,021

[57] ABSTRACT A shipping container is described for large, heavy plumbing fixtures, such as bathtubs and the like. The container includes a pair of cut and scored end frames [22] Filed:

that are positioned at each end of the bathtub in combination with a pair of separate cushioning pads, and, a continuous wrapper element which encloses the bathtub. The wrapper is secured to the sides of the end frames and includes top, bottom and side panels 4 new 1 w .Q 3 gm 4 1% w m 0 2 0 3 2 6 m 5 mfir. m m GUM .M .w UmF H N 555 [56] References Cited UNITED STATES PATENTS which extend around the bathtub to provide a durable,

206/320 convenient, and inexpensive shipping container. Kivell 206/320 206/320 4 Claims, 9 Drawmg Flgures SHEET 2 [IF 3 PATENTEU m 1 9197 5 BATHTUB PACKAGE SUMMARY OF INVENTION The present invention relates to a shipping container, and more particularly to a shipping container for large, heavy plumbing fixtures, such as bathtubs and the like.

Large, heavy plumbing fixtures require specially constructed shipping containers to prevent them from being damaged during shipping, storage, or other handling. Bathtubs in particular are difficult to package because of their large size and weight, their irregular shape, and the susceptibility of their vitreous surfaces to chips and scratches.

In the past, plumbing fixtures such as bathtubs were packaged and shipped in containers fabricated from wood or corrugated fiberboard or a combination thereof. However, the known containers were expensive to manufacture and required considerable effort and time for positioning the bathtub Within the container. Moreover, the known containers did not provide any specially adapted structure for supporting the portions of the bathtub best suited for bearing the weight of the tub during shipment. In addition, the known containers provided only minimal support means with the primary structure of the container for supporting and spacing the bathtub from the sides of the wrapper enclosing the tub.

Accordingly, it is the basic object of this invention to provide an improved means for enclosing, protecting and facilitating the handling of heavy plumbing fixtures such as bathtubs, however, it should be clear after considering the disclosure herein as a whole, that other similarly shaped objects could just as readily be packaged with the novel container described using the same principles set forth.

More specifically, it is the principal object of this invention to provide a shipping container for bathtubs which is low in cost; convenient and easy to store, handle and assemble; is effective in protecting the bathtub during shipment; is durable so as to resist both rough handling and exposure to the elements; has a smooth and neat exterior design for ease of handling; has convenient and effective hand hole cut outs and inspection ports; has large areas provided for printed or other advertising matter; and, is easy and quick to assemble and disassemble.

Briefly, these objects are attained in the shipping container disclosed herein by the use of novel reinforced end frames in combination with an outer wrapper element which completely encloses the bathtub upon assembly. Each novel end frame comprises a cut and scored panel which is folded into three sections, with the central or intermediate section being arranged adjacent to and in contact with the packaged bathtub while the two remaining end sections are offset from the intermediate section, and lie substantially at the extreme outer edge ends of the bathtub outer wrapper. Each end frame also includes an articulated flap at one end thereof which folds around to provide added protection to the front apron of the packaged bathtub. And each end frame member also includes a flap located along the lower edge of the intermediate section for protecting the extreme ends of the packaged bathtub. Accordingly, the novel end frame members disclosed herein derive their strength primarily from the fact that they are folded to fit snugly against the ends of the bathtub and because they are securely fastened to the outer wrapper which encloses the bathtub.

A significant contribution to the attainment of the overall combination of advantages set forth above lies in the fact that the shipping container disclosed herein, including the novel end frame members and suspension elements is constructed completely from corrugated paperboard. In addition, each of the basic elements which make up the parts of the shipping container disclosed herein, may be shipped to the user in flat blank form where they may be set-up quickly and easily for packaging the bathtubs. Furthermore, in one embodiment of the present invention, each end frame member is provided with a slot near the sides of the intermediate section thereof for correctly positioning, and, maintaining the position of the end frames, with respect to the outer wrapper of the container and the die-cut suspension elements, thereby permitting assembly of the container on a table or an assembly line with semiautomatic convenience.

In summary, the invention to be described in more detail hereinafter attains each and every one of the objectives set forth above. Moreover, further objects, advantages and details will become evident from the following description, drawing and claims.

DESCRIPTION OF PRIOR ART Bathtub containers of the class disclosed herein are known and are shown in the following US. Pat. Nos, 3,289,825; 3,521,744; 3,486,779; 3,386,567; 3,099,351; 3,487,9l4; 3,680,688; 3,757,935; and, 3,773,17l. However in each of the patents indicated, the constructions described have either been too expensive, too complicated to set up or otherwise unsatisfactory. Thus to overcome the problems inherent in the beforementioned prior art the bathtub container of the present invention was designed.

IN THE DRAWING FIG. 1 shows in blank form the outer wrapper of the present invention;

FIG. 2 shows in blank form one of the end frame members required for the present invention;

FIG. 2A is a fragmentary plan view showing a modification for the blank of FIG. 2;

FIG. 3 shows a partial view in blank form of one of the die cut suspension elements used in the present invention;

FIG. 4 is a perspective view showing the diecut blank of FIG. 3 folded into its suspension element configuration;

FIG. 5 is a partial perspective view from the end showing a bathtub positioned on the outer wrapper with a suspension element in place;

FIG. 6 is a partial perspective view similar to FIG. 5 showing an end frame member arranged for final assembly;

FIG. 7 is a partial perspective view similar to FIG. 6 showing the container in its next stage of assembly; and,

FIG. 8 is a perspective view showing the bathtub wrapper completely closed and ready for shipment.

DETAILED DESCRIPTION The principal parts of the present invention comprise an outer wrapper 10 shown in FIG. 1, a pair of end frame members 30 (one shown in FIG. 2 in blank form) and a pair of die-cut suspension elements for'each end of the bathtub. The outer Wrapper includes, in'no particular order, a series of panels 11, l2, l3 and 14 which form the bottom, top and side panels of the outer enclosure. Each of the panels 11, 12, 13 and 14 are separated from one another along fold lines 15, 16 and 17 with an additional fold line 18 separating panel l4'fr'om the closure flap 19. The outer wrapper 10, as shown in FIG. 4, lies flat before it is folded around thetub. However, after it is around the bathtub, the closure flap 19 is secured to the first panel 11 by any known and desirable means including staples, adhesive or stitching. Finally, the outer wrapper 10 also includes end flaps'23, 24 at each end of'the panels 11, l2, l3 and 14 for folding inwardly at the ends of the outer wrapper in a manner to be subscribed more fully hereinafter.

FIG. '2 illustrates in blank form oneof a required pair of end frame members for the shipping container dis closed herein. The end frame member 30 comprises a single blank of corrugated paperboard material which is cut and scored to form three primary panels '31, 32, 33, a pair of secondary panels 40,41, an end flap 38, and, a lower flap element 44 foldably attached to the centrally located or intermediate primary panel 32. The blank is divided into the primary and secondary panels by parallel and spaced apartfold lines 34, 35 and 36, 37 while end flap 38 is connected to panel 31 along a fold line 39 and lower flap 44 is connected to panel 32 along fold line-45. The end'frame member blank is also preferably notched along its lower edge at 42, 43 in the region defined by the fold lines 34-35 and 36-37 for a height that is substantially equal to the height of the separate cushioning pads plus the thickness of the flanged end of the bathtub. Meanwhile, the fold line 45 dividing-panel 32 from lower flap 44 is arranged to be substantially coterminous with the height of the notched slots 42, 43. In addition, the blank member shown in FIG. 2 also preferably includes a pair of strategically located hand hole cut outs 46, 47 in primary panels 31, 33 respectively, and may include an inspection port as shown at 48 in panel 32. Thus,'the primary panels 31 and 33 form the extreme ends of the finished container and serve as the elements to which the end flaps 23, 24 of outer wrapper 1 may besecured. End flap 38 is arranged in the assembled condition of the container as a protective and cushioning means for the front apron of the bathtub and lower flap 44 when assembled lies underneath the side flange of the bathtub. Meanwhile, when properly folded for assembly, the secondary panels 40, 4] lie substantially perpendicular to the primary panels 31, 33 and 32, and when so arranged urge the panel 32 into contact with the adjacent end of the bathtub proper. This orientation urges the lower flap 44 into its assembled position underneath the side flange of the bathtub which enables the panel 32 to also serve as a suspension strut in the fully assembled condition of the package.

FIG. 3 shows the die cut blank which is used to form one of the two end suspension elements required for a complete package. Blank 60 includes a plurality of alternating, longitudinal and spacedap'art cut lines 61 and fold lines'62 for forming the desired height of the cushioning element 65. As shown in FIG. 3, the lines 61 and 62 are each formed by cuts applied to opposite sides of the blank. The cuts penetrate the'blank material for a distance of about one-half the thickness of the material itself and thereby fo'rm fold lines on the sides of the blankopposite' the cuts. In this condition the cut and scored blanks serve to produce a suspension pad having a height equal to four thicknesses of the blank material. Obviouslymore or less lines could be used to produce a pad having greater or lesser height. In addition, the blank 60 of FIG. 3 also includes a separate fold line 63 alongone edge thereof for forming the edge flap 64 which is folded either outside of the end frame primary panels 31', 33 or behind the same panels in the case where slots 43and 42 are included in the end frame member 30. The latter condition is illustrated particularly in FIG. 2A wherein one slot 43' is shown. In the preferred embodiment of the present invention, the suspension pad cushioning elements 65 are simply laid loosely between the outer wrapper l0 and the side flanges of the'bathtub (see FIG. 5), however it is within the scope of the present invention to fix or attach the cushioning elements 65 to the outer wrapper 10 as an alternate method for the'packaging of the bathtub. In addition, the cushioning elements 65, in the preferred embodiment are fabricated from a serially scored blank of paperboard fol'dedinto overlapping relationshipto achieve the, desired thickness. However, it should be apparentthat a serially scored and glued sheet of corrugated paperboard could just as readily be employed. Furthermore, wooden, plastic, or foam elements, or even fiberboard elements could be used in place of thepreferred corrugated paperboard cushioning elements described herein.

FIG. 5 illustrates the manner in which the outer wrapper 10 and one of the cushioning padsuspension elements 65 are arranged. Note that the bathtub 54 is turned upside down with the front apron or skirt 50 I thereof forward. The bathtub also includes a top flange 53 and a pair of rear legs 51, 52. Thus,- the type of bathtub illustrated is one .that is built into a space provided therefor in the bathroom. Other bathtubs of a different style.which are not built in may include skirts or aprons ateach end thereof.

For the purpose of assembling the package reference should be made to FIGS. 5 and 6. The wrapper 10 is initially laid out. as illustrated with the scored side up, a suspension member is placed between the wrapper and the end flange of the bathtub and an end frame member is fitted to the end of the tub. In the case illustrated, the suspension pad is loosely positioned on the outer wrapper l0, however as pointed out hereinbefore, each of the cushioning pads could just as readily be fixed to the outer wrapper or otherwise located thereon as a first step in the assembly of the package. The end frame member 30 is fitted to the end of the bathtub as follows. First, the paperboard blank is broken at fold lines 34, 35 and 36, 37 to orient the centrally located panel 32 offset rearwardly from the remaining two primary panels 31, 33. The lower edge flap 44 is folded upwardly in the direction of theprimary panels 31, 32 and in this condition the end frame member is urged toward the end of the bathtub (FIG. 6). Subsequently, side flap 38 is folded around about the fold line 39 to lie in face-toface contact with the front apron of the tub. It will also be noted from a careful review of FIG. 6 that in a preferred embodiment the edge flap 64 of suspension pad 65 located outside the panels 31, 33 and between the sai'clpanels and the edge flap 24 of outer wrapper panel 13. 'As pointed out hereinbefore, if desired, the edge flap 64 could be fitted between the edge flange 53 of the bathtub and the panels 31, 33 simply by providing an elongated slot 43', as shown in FIG. 2A. extending from each of the notched slots 42 and 43 in the region of the fold lines 34 and 37, each said slot having a length substantially equal to the width of the edge flap 64.

FIG. 7 shows the next step in the assembly of the package wherein the outer wrapper 10 is folded around and secured to the end frame panels 31, 32 and to itself. And, FIG. 8 shows the complete package ready for shipment.

Thus, the novel end frame members in conjunction with the cushioning pads 65 of the present invention clearly offer reinforced support and protection to the packaged tub both from the top and sides of the flange 53 of the tub. In addition, with the side flap 38 of end frame panel 31 folded around into contact with the apron 54 of the tub, additional space is provided along the front of the apron 54 to prevent damage thereto. Accordingly, the bathtub is located within the package so as to be spaced from the walls thereof. and the end frame members 30 present the panels 31 and 33 thereof in a position which enables the end flaps 23 and 24 of the outer wrapper panels 11, l2, l3 and 14 to be safely secured thereto. Moreover, the height of the panels 31, 32, 33 of the end frame members 30 is chosen so as to provide a clearance over the feet 51, 52 of the bathtub when the outer wrapper is folded around the tub and secured together along the closure flap 19.

The preferred method for securing the end flaps 23, 24 of the outer wrapper panels 11-14 to the end frame panels 31 is by stapling, however other securing means could just as readily be used. Furthermore, as pointed out hereinbefore, simply by securing the end flaps 23, 24 to panels 31 and 33, yields additional integrity and strength to the entire package. With the end flaps 23, 24 so attached, and, with the end frame member 30 in position to place the centrally located panel 32 in closely abutting relationship to the end and the flange 53 of the tub, the tub becomes more than adequately located within the container to achieve each of the advantages pointed out in the objects of the invention.

By providing end frame members 30 and suspension pads 65, fitted to the ends of the packaged bathtub, in combination with a continuous wrapper that not only surrounds all sides of the bathtub, but is also attached to the end frame members, a package is achieved which protects all of the vitreous coated surfaces of the bath tub that are especially susceptible to damage. Moreover, the complete enclosure provided by the present invention prevents the entry of any debris or other foreign matter into the package. And a smooth exterior surface is achieved on all sides of the container to permit ease of handling.

The invention disclosed herein provides a new and improved shipping enclosure, that, compared with the prior art packages, is considerably less expensive in terms of costs of material and labor involved in construction. assembly and disassembly. Further. the novel container disclosed herein provides a lightweight, strong and durable shipping enclosure for packaging bathtubs that resists twisting, and that protects the bathtub against damage during shipment and when stored.

The invention in its broader aspects is not limited to the specific details shown and described, and changes therein may be made in such details without departing from the principles of the invention as disclosed in the appended claims.

1 claim:

1. A shipping container for bathtubs or the like in the form of a complete enclosure for said bathtub, comprising:

a. a single sheet outer wrapper portion including a series of interconnected panels which extend around the top, bottom and sides of said bathtub, said interconnected panels further including end flaps foldably attached at each end thereof;

b. a pair of end frame members fitted to the ends of said bathtub, each of said end frame members comprising a plurality of separate panels consisting of three primary panels, a pair of secondary panels, an end flap and a lower flap element formed side-byside in a single blank of foldable material and arranged to support the ends of said bathtub in spaced relation from the ends of said outer wrapper wherein, the three primary panels are arranged so that two of said primary panels lie in a substantially common plane at the extreme edge of the bathtub outer wrapper and a third primary panel intermediate said two primary panels lies in an offset and substantially parallel plane adjacent to and in contact with the packaged bathtub, the two secondary panels lie in substantially parallel and spaced apart planes and connect the intermediate primary panel with the remaining two primary panels, the end flap is connected to the leading edge of one of the two primary panels and is folded around for protecting and cushioning the front face of the bathtub, and the lower flap element is connected to the lower end of said intermediate panel and is folded to lie adjacent and in contact with the lower surface of the side end flange of said bathtub;

c. a pair of suspension pads separate from said end frame members and arranged to lie at each end of said bathtub between the single sheet outer wrap per and the two side end flanges of said bathtub; and,

d. means for fastening the outer wrapper panel end flaps to the said end frame members and the suspension pads.

2. The shipping container of claim 1 wherein each end frame member is notched at its lower edge in the region formed by said secondary panels for a height that is substantially equal to the height of the separate cushioning pad at the edge of the bathtub plus the thickness of the flanged end of the said bathtub.

3. The shipping container of claim 2 wherein each suspension pad includes a flap element along one edge thereof that is sandwiched between the two end primary panels of each end frame member and the adjacent outer wrapper panel end flap in the assembled condition.

4. The shipping container of claim 2 wherein a slot is provided in each end frame member in the region of the opposed edges of said notched areas to permit the flap elements of each suspension pad member to be inserted between the two end primary panels of each end frame member and the flanged edge of the said bath- 

1. A shipping container for bathtubs or the like in the form of a complete enclosure for said bathtub, comprising: a. a single sheet outer wrapper portion including a series of interconnected panels which extend around the top, bottom and sides of said bathtub, said interconnected panels further including end flaps foldably attached at each end thereof; b. a pair of end frame members fitted to the ends of said bathtub, each of said end frame members comprising a plurality of separate panels consisting of three primary panels, a pair of secondary panels, an end flap and a lower flap element formed side-by-side in a single blank of foldable material and arranged to support the ends of said bathtub in spaced relation from the ends of said outer wrapper wherein, the three primary panels are arranged so that two of said primary panels lie in a substantially common plane at the extreme edge of the bathtub outer wrapper and a third primary panel intermediate said two primary panels lies in an offset and substantially parallel plane adjacent to and in contact with the packaged bathtub, the two secondary panels lie in substantially parallel and spaced apart planes and connect the intermediate primary panel with the remaining two primary panels, the end flap is connected to the leading edge of one of the two primary panels and is folded around for protecting and cushioning the front face of the bathtub, and the lower flap element is connected to the lower end of said intermediate panel and is folded to lie adjacent and in contact with the lower surface of the side end flange of said bathtub; c. a pair of suspension pads separate from said end frame members and arranged to lie at each end of said bathtub between the single sheet outer wrapper and the two side end flanges of said bathtub; and, d. means for fastening the outer wrapper panel end flaps to the said end frame members and the suspension pads.
 2. The shipping container of claIm 1 wherein each end frame member is notched at its lower edge in the region formed by said secondary panels for a height that is substantially equal to the height of the separate cushioning pad at the edge of the bathtub plus the thickness of the flanged end of the said bathtub.
 3. The shipping container of claim 2 wherein each suspension pad includes a flap element along one edge thereof that is sandwiched between the two end primary panels of each end frame member and the adjacent outer wrapper panel end flap in the assembled condition.
 4. The shipping container of claim 2 wherein a slot is provided in each end frame member in the region of the opposed edges of said notched areas to permit the flap elements of each suspension pad member to be inserted between the two end primary panels of each end frame member and the flanged edge of the said bathtub. 